Exercising Generator Set; Operations In Cold Weather Climates; Controller Operation - Kohler KG40 Operation

2.2 Exercising Generator Set

DANGER
Operate the generator set under load once each week for one hour. Perform the exercise in the presence of an operator when
the generator set does not have an automatic transfer switch with an exercise option.
During the exercise period, apply a minimum of 35% load based on the nameplate standby rating, unless otherwise instructed
in the engine operation manual.
The operator should perform all of the prestart checks before starting the manual exercise procedure. Start the generator set
according to the starting procedure in the section titled: Controller Operation. While the generator set is operating, listen for a
smooth-running engine and visually inspect generator set for fluid or exhaust leaks.
The generator set controller does not provide weekly scheduled exercise periods. For scheduled exercise periods, refer to the
automatic transfer switch (if equipped) literature.

2.3 Operations in Cold Weather Climates

Cold weather operation is generally considered ambient temperatures below freezing 0°C (32°F). The following items are
recommended for cold weather starting and/or operation when the unit is located in an enclosure or unheated structure. Have a
licensed electrician install 120 VAC, 15 amp outlets as needed if not already in the immediate area.
Refer to the engine operation manual regarding engine oil viscosity, fuel composition, and coolant mixture recommendations.

The engine block heater is generally recommended for most units when operated below 0°C (32°F) and required as
part of NFPA 110. Refer to the respective spec sheet for temperature recommendations in available options.

A battery heater is generally recommended for most units when operated below 0°C (32°F). Refer to the respective
spec sheet for model availability.

An alternator strip heater is available for most generator sets providing a heat source to prevent moisture and frost
buildup.

The crankcase ventilation (CCV) heater kit provides a controlled heating source to the crankcase ventilation system
preventing freezing water buildup during cold weather. The thermostat turns on at 4°C (40°F) and turns off at
16°C (60°F). Refer to the section titled: Scheduled Maintenance for more information. (Applies to 125/150 kW,
8.1 L GM-and 8.8 L PSI- powered generator set models only.)

Heater tape is recommended when the generator set is equipped with a closed crankcase ventilation system and
operated at or below 50% of rated load. Wrap the UL/CSA compliant heater tape around the crankcase
canister/breather system hose that runs from the crankcase to the air intake and use cable ties as needed to secure
the heater tape. If the heater tape is within 152 mm (6 in.) of the exhaust system, use thermal insulation material to
protect the heater tape.
40- 60REOZK Models only. When the ambient temperature drops below - 15°C (5°F) a turbocharger pre-lube sequence begins
when the crank cycle is initiated. During the first 10 seconds of cranking, the fuel system is disabled to ensure engine oil is
present at the turbocharger. This is necessary for the longevity of the turbocharger on the KDI 3404TM engine. The fuel system
is then enabled for the next 5 seconds of cyclic cranking and the engine will start as normal.

2.4 Controller Operation

The controller operation includes several types of starting and stopping functions as detailed in the following paragraphs. The
controller master control switch buttons, lamps, and alarm horn functions are summarized in the figure titled: Master Control
Button Function Summary.
44
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
TP-6694 6/22